US20050138499A1 - System and method to test integrated circuits on a wafer - Google Patents
System and method to test integrated circuits on a wafer Download PDFInfo
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- US20050138499A1 US20050138499A1 US10/707,205 US70720503A US2005138499A1 US 20050138499 A1 US20050138499 A1 US 20050138499A1 US 70720503 A US70720503 A US 70720503A US 2005138499 A1 US2005138499 A1 US 2005138499A1
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- 238000000034 method Methods 0.000 title claims description 26
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
- G01R31/00—Arrangements for testing electric properties; Arrangements for locating electric faults; Arrangements for electrical testing characterised by what is being tested not provided for elsewhere
- G01R31/28—Testing of electronic circuits, e.g. by signal tracer
- G01R31/302—Contactless testing
- G01R31/3025—Wireless interface with the DUT
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
- G01R31/00—Arrangements for testing electric properties; Arrangements for locating electric faults; Arrangements for electrical testing characterised by what is being tested not provided for elsewhere
- G01R31/28—Testing of electronic circuits, e.g. by signal tracer
- G01R31/2851—Testing of integrated circuits [IC]
- G01R31/2884—Testing of integrated circuits [IC] using dedicated test connectors, test elements or test circuits on the IC under test
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
- G01R31/00—Arrangements for testing electric properties; Arrangements for locating electric faults; Arrangements for electrical testing characterised by what is being tested not provided for elsewhere
- G01R31/28—Testing of electronic circuits, e.g. by signal tracer
- G01R31/2851—Testing of integrated circuits [IC]
- G01R31/2886—Features relating to contacting the IC under test, e.g. probe heads; chucks
- G01R31/2889—Interfaces, e.g. between probe and tester
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
- G01R31/00—Arrangements for testing electric properties; Arrangements for locating electric faults; Arrangements for electrical testing characterised by what is being tested not provided for elsewhere
- G01R31/28—Testing of electronic circuits, e.g. by signal tracer
- G01R31/302—Contactless testing
- G01R31/303—Contactless testing of integrated circuits
Definitions
- the present invention relates to integrated circuits, semiconductor chips and the like, and more particularly to a to a system and method to test an integrated circuit, semiconductor chip on a wafer.
- Testing integrated circuits, semiconductor chips and the like at various stages of the manufacturing process can be advantageous as processing adjustments may be made or other remedial operations may be performed to realize higher yields. Capturing information regarding fluctuations and failures during the manufacturing process can have a substantial impact on the overall product cost. For some emerging forms of regular logic, back-end-of-line (BEOL) processing adjustments and changes could be made to permit substantially complete utilization of what would otherwise be partially non-functioning silicon.
- BEOL back-end-of-line
- wafer probe testing One means of testing chips during various stages of the manufacturing process is wafer probe testing.
- Wafer probe testing is costly and limited in terms of the extent to which it may be used.
- the wafers must be maintained in their manufacturing environment.
- wafer probe testing of all chips and collecting test data from all chips in the manufacturing environment is impractical.
- the environmental issues are less of a problem, but the process is still costly.
- probe testing is still time consuming and therefore costly and issues exist with respect to contact resistance associated with the probes which can impact overall yield.
- a system to test integrated circuits, semiconductor chips or the like formed on a wafer may include a transceiver formed on the wafer.
- the system may also include an antenna system that is couplable to the transceiver.
- the transceiver may be formed in one of a scribe line formed on the wafer, on each of the integrated circuits or dies to be tested, on another chip or die on the wafer, or in an unusable portion of the wafer.
- the antenna system may be formed in at least one of the same scribe line as the transceiver, in at least one other scribe line formed in the wafer, on each of the integrated circuits or dies to be tested, on another chip or die on the wafer or on an usable portion of the wafer.
- the antenna or antenna system may also be external to the wafer and the transceiver may be coupled to the antenna by a wafer boat, handler or similar fixture that holds the wafer during manufacturing.
- a system to test integrated circuits, semiconductor chips or the like formed on a wafer may include a plurality of transceivers. Each transceiver may be adapted to receive and transmit signals to test selected ones of a multiplicity of integrated circuits or the like formed on the wafer. Each of the transceivers may be formed at different locations on the wafer. Each transceiver may be formed in at least one of a plurality of scribe lines formed on the wafer, on each die or integrated circuit to be tested, on another die or chip on the wafer or on an unusable portion of the wafer.
- the system may also include a plurality of antenna systems. Each antenna system may be couplable to at least one of the plurality of transceivers.
- Each of the plurality of antenna systems may be formed at different locations on the wafer in at least one of the plurality of scribe lines, on a chip on the wafer or on an unusable portion of the wafer.
- the antenna or antenna system may be external to the wafer and the transceivers may be coupled to the antenna by a wafer boat or fixture used to hold the wafer during the manufacturing process.
- a transceiver to test integrated circuits or the like formed on a wafer may include a down converter to convert a received radio frequency (RF) signal to an intermediate frequency (IF) signal.
- the transceiver may also include a received signal strength indicator (RSSI) and an amplifier to amplify the IF signal in response to the RSSI.
- the transceiver may also include a comparator to generate a data signal in response to an amplified IF signal.
- a transceiver to test integrated circuits or the like formed on a wafer may include a phase/frequency detector to receive an input or reference signal.
- a charge pump may be provided to receive an output signal from the phase/frequency detector.
- a filter may filter signals in a selected frequency band from the charge pump.
- a voltage controlled oscillator may receive the filtered signal from the filter and a power amplifier may modulate a carrier frequency from the voltage controlled oscillator.
- an antenna system to test integrated circuits or the like formed on a wafer may include a loop antenna or the like adapted to be shared by a plurality of transceivers.
- the antenna system may also include a plurality of differential amplifier circuits.
- Each differential amplifier circuit may be associated with one of the plurality of transceivers, wherein only one of the plurality of differential amplifier circuits may be active at any given time to permit the associated transceiver to receive or transmit signals.
- a method of making a system to test integrated circuits or the like formed on a wafer may include forming a transceiver on the wafer.
- the method may also include providing an antenna system that is couplable to the transceiver.
- the transceiver may be formed in at least one of a scribe line formed on the wafer, on each die or integrated circuit to be tested, on another die or chip on the wafer, or on an unusable portion of the wafer.
- the antenna system may be formed in at least one of the same scribe line as the transceiver, in at least one other scribe line formed in the wafer, a die or chip on the wafer or an unusable portion of the wafer.
- the antenna or antenna system may be external to the wafer.
- a method to test integrated circuits or the like formed on a wafer may include selecting at least one integrated circuit of a plurality of integrated circuits to be tested. The method may also include performing a test or self-test on the at least one selected integrated circuit and transmitting test results via a transceiver associated with the at least one selected integrated circuit.
- FIG. 1 is top elevation view of a wafer on which integrated circuits or the like are formed.
- FIG. 2 is a block diagram of a system to test integrated circuits or the like formed on a wafer in accordance with an embodiment of the present invention.
- FIG. 3 is a block schematic diagram of a system to test integrated circuits or the like formed on a wafer in accordance with another embodiment of the present invention.
- FIG. 4 is a partial cross-sectional view of a wafer illustrating a conductive layer to connect to transceivers formed on the wafer in accordance with an embodiment of the present invention.
- FIG. 5 is a block diagram of an example of a transceiver that may be used in a system to test integrated circuits or the like in accordance with an embodiment of the present invention.
- FIG. 6 is a schematic diagram of an example of an antenna system that may be used in a system to test integrated circuits or the like in accordance with an embodiment of the present invention.
- FIG. 1 is top elevation view of a wafer 100 on which integrated circuits 102 , semiconductor chips or the like are formed.
- Each of the integrated circuits 102 are separated by scribe lines 104 formed in a surface of the wafer 100 .
- a first plurality 104 a of scribe lines may extend parallel to one another in one direction or substantially horizontally across the surface or the wafer 100 .
- a second plurality 104 b of scribe lines may extend substantially parallel to one another in a different direction or substantially orthogonal to the first plurality 104 a of scribe lines.
- the scribe lines 104 a and 104 b may form substantially square or rectangular areas that each define an integrated circuit 102 or semiconductor chip.
- the scribe lines 104 a and 104 b may be used to separate each of the integrated circuits after fabrication.
- the scribe lines 104 a and 104 b may have a selected width “W” to permit components of a system, such as a system 200 to test integrated circuits illustrated in FIG. 2 or other systems, to be formed within the scribe lines 104 a and 104 b .
- the selected width “W” of the scribe lines may be about 200 microns or more.
- the system as described in more detail herein may be used to test the integrated circuits 102 on the wafer 100 at various stages during the manufacturing process. In at least one embodiment of the present invention, the system may be employed without the use of probes to test the integrated circuits 102 .
- FIG. 2 is a block diagram of a system 200 to test integrated circuits (ICs) 202 , semiconductor chips or the like formed on a wafer 204 in accordance with an embodiment of the present invention. Only a portion of the wafer 204 and integrated circuits 202 are shown in FIG. 2 for purposes of explanation and clarity.
- the integrated circuits 202 and wafer 204 may be similar to the integrated circuits 102 and wafer 100 illustrated in FIG. 1 .
- the system 200 may include a transceiver 206 formed in a scribe line 208 of the wafer 204 . In other embodiments of the present invention, the transceiver 206 may be formed at other locations on the wafer 204 .
- the transceiver 204 may be formed on the die or as part of the integrated circuit 202 being tested for self-testing or the like. Alternatively, the transceiver 204 may be formed in another chip or die portion of the wafer 204 that is not used to form an integrated circuit or in an unusable portion of the wafer 204 , such as the area 106 in FIG. 1 .
- the system 200 may also include an antenna system 210 that is couplable to the transceiver 206 to receive and transmit signals to and from the transceiver 206 .
- the antenna system 210 may also be formed in at least one scribe line 208 formed in the wafer 204 or on a surface of the wafer 204 .
- the antenna system 210 may be formed in the same scribe line 208 as the transceiver 206 , or in another embodiment, the antenna system 210 may be formed in one or more scribe lines 208 of the wafer 204 .
- the antenna system 210 may also be formed at other locations on the wafer 204 .
- the antenna system 210 or systems may be formed on each die or chip 202 to be tested, on another chip or die portion on the wafer 204 that is not used to form an integrated circuit or on an unusable portion of the wafer 204 .
- the antenna system 210 may include a loop antenna, a dipole antenna or the like, or the antenna system 210 may be an antenna array formed by loop elements, dipole elements or similar elements.
- the transceiver 206 may be coupled to a plurality of integrated circuits 202 by a multiplexing circuit 212 or the like to test selected ones of the plurality of integrated circuits 202 .
- the transceiver 206 may be adapted to apply test signals to at least one selected integrated circuit 202 to test the selected integrated circuit 202 in response to the antenna system 210 receiving a testing signal or a similar signal.
- the antenna system 210 may be adapted to receive testing signals and to transmit signals corresponding to results from the testing of the at least one selected integrated circuit 202 .
- an integrated circuit 202 to be tested and an associated transceiver 206 may be selected by at least one of a word-line 214 or a bit-line 216 .
- Word-lines 214 and bit-lines 216 are electrically conductive traces of metallization or other conductive material that may be formed in the scribe lines 208 .
- the word-lines 214 may extend in one direction across the wafer 204 and the bit-lines 216 may extend substantially orthogonal to the word-lines 214 across the wafer 204 .
- the word-lines 214 and bit-lines 216 may be accessed proximate to a periphery or edge of the wafer 204 .
- Each integrated circuit 202 may be electrically connected to at least one word-line 214 and to at least one bit-line 216 so that each integrated circuit 202 may be addressed by at least one associated word-line 214 and bit-line 216 .
- the word-lines 214 and bit-lines 216 may then be used to address or select a specific integrated circuit 202 for testing or for other purposes, such as to send and receive signals from selected integrated circuits 202 , powering selected integrated circuits 202 or the like.
- the word-lines 214 and bit-lines 216 may form a selected distribution scheme 218 or pattern in the scribe lines 208 to facilitate selecting an integrated circuit or circuits 202 to be tested and an associated transceiver or transceivers 206 .
- the word-line/bit-line distribution scheme 218 may also be used or may be alternatively used to distribute test mode power to the selected integrated circuit 202 to be tested and the associated transceiver 206 .
- the transceiver 206 may receive power via one of a probe, a radio frequency power signal or a pad 220 electrically connected to the transceiver 206 in addition to a word-line or a bit-line.
- the pad 220 may be formed proximate to a periphery of the wafer 204 .
- the pad 220 may be electrically connectable to a power source 222 external to the wafer 204 . Only one pad 220 is shown in FIG. 2 for purposes of explanation; however, multiple pads similar to pad 220 may be formed at selected location around the periphery of the wafer 204 to distribute power to other transceivers formed on the wafer 204 .
- an associated transceiver 206 may be adapted to select a proper stream of test data for the particular integrated circuit 202 under test from the multiplexing circuit 212 .
- the transceiver 206 may then transmit the resulting test data to an external transceiver or test unit (not shown in FIG. 2 ) via the antenna system 210 .
- the transceiver 206 may be adapted to provide one of an amplitude shift keying (ASK) modulation scheme, on-off keying (OOK) modulation or a similar modulation scheme that may permit the architecture of the transceiver 206 to be relatively simple for formation of the transceiver 206 in the scribe line 208 .
- ASK amplitude shift keying
- OOK on-off keying
- the transceiver 206 may receive and transmit signals to perform real-time tests periodically during fabrication of the wafer 204 , such as during burn-in stress conditions or under other environmental extremes. While only one transceiver 206 and antenna system 210 are shown in FIG. 2 for purposes of clarity and explanation, the system 200 may include a plurality of transceivers 206 and antenna systems 210 similar to the system 300 illustrated in FIG. 3 . The transceivers 206 and antenna systems 210 may be located at selected locations or in a predetermined distribution to efficiently permit testing of any and all integrated circuits 202 formed on the wafer 204 .
- FIG. 3 is a block schematic diagram of a system 300 to test integrated circuits formed on a wafer 302 , similar to integrated circuits 102 and 202 of FIGS. 1 and 2 .
- the system 300 may be similar to the system 200 of FIG. 2 .
- the system 300 may include a plurality of transceivers 304 .
- Each of the transceivers 304 may be adapted to receive and transmit signals to test selected ones of a multiplicity of integrated circuits (not shown in FIG. 3 ), similar to integrated circuits 102 and 202 of FIGS. 1 and 2 respectively.
- Each of the transceivers 304 may be formed at a different location on the wafer 302 in at least one of a plurality of scribe lines 306 formed in the wafer 302 .
- Each of the transceivers 304 may be coupled to one or more integrated circuits to test selected ones of the integrated circuits.
- a multiplexing circuit similar to the multiplexing circuit 212 shown in FIG. 2 may be provided to couple each transceiver 304 to associated ones of the plurality of integrated circuits.
- the system 300 may also include a plurality of antenna systems 308 .
- Each antenna system 308 may be coupled to at least one of the plurality of transceivers 304 .
- Each antenna system 308 may also be formed at different locations on the wafer 302 in one or more of the scribe lines 306 .
- the transceivers 304 , antenna systems 308 and scribe lines 306 are not shown to scale relative to the wafer 302 and are illustrated as being much larger than actuality for purposes of explaining the present invention. As previously described, the scribe lines may be on the order of about 200 microns or more in width.
- Each of the transceivers 304 and antenna systems 308 may be formed in a predetermined distribution on the wafer 302 .
- the predetermined distribution may be adapted to effectively and efficiently test all integrated circuits at various stages of the manufacturing process and to facilitate optimum testing of a selected number of integrated circuits simultaneously.
- the predetermined distribution may also be adapted to minimize space utilization and to minimize electromagnetic interference with the integrated circuits during testing and between different transceivers 304 and associated antenna systems 308 .
- Each transceiver 304 or each transceiver in a subset of transceivers 304 of the plurality of transceivers may each be adapted to receive testing signals and to transmit test result signals simultaneously on different radio frequencies or channels.
- each of the transceivers 304 may be adapted to provide one of an amplitude shift keying (ASK) modulation, on-off keying (OOK) modulation or a similar modulation scheme.
- Each of the transceivers 304 may also be adapted to receive and transmit signals to perform real-time tests or other operations periodically during fabrication of the wafer 302 .
- the transceiver 304 may be adapted to transmit and receive signals to perform tests under burn-in stress conditions or other environmental conditions.
- the system 300 may also include another transceiver or a system transceiver and test unit 310 that may be located external to the wafer 302 .
- the system transceiver 310 may be adapted to transmit scan test vectors or other signals to selected ones of the transceivers 304 on the wafer 302 and to receive test results from the selected transceivers 304 .
- Each of the transceivers 304 may communicate with the system transceiver 310 on different radio frequencies or channels.
- the transceivers 304 may transmit self-test data and receive and transmit scan test vectors form the external system transceiver and test unit 310 .
- the system transceiver 310 may transmit and receive RF signals via an antenna 312 .
- the transmit power from the wafer 302 as well as the external transceiver 310 and antenna 312 may be kept at a low enough level so that the coverage is within a predetermined distance “D.”
- the predetermined distance “D” may be on the order of about one meter.
- one or more antennas 314 or an antenna system provided external to the wafer 302 may be coupleable to each of the transceivers 304 .
- the transceivers 304 may be coupled to the antenna 314 via a wafer boat 316 , wafer handler or other fixtures that may hold the wafer 302 during the manufacturing process.
- the transceivers 304 may transmit and receive signals via the antenna 314 to test the integrated circuits formed on the wafer 302 or for other purposes.
- an antenna 318 may be integrally formed or attached to the wafer boat 316 as an alternative to external antenna 314 .
- the external antenna 314 or the wafer boat antenna 318 may be provided in addition to the antenna systems 308 formed in the scribe lines 306 or as alternatives to the antenna systems 308 .
- FIG. 4 is a partial cross-sectional view of a wafer 400 illustrating a conductive layer 402 to connect to transceivers 404 formed in scribe lines 406 on the wafer 400 in accordance with an embodiment of the present invention.
- the transceivers 404 similar to the transceivers 206 and 304 of FIGS. 2 and 3 , respectively, may be formed in the scribe lines 406 that are formed in a substrate 408 of the wafer 400 .
- Integrated circuits (not shown in FIG. 4 ) formed on the wafer 400 may be tested during the manufacturing process by depositing or forming a layer 410 of dielectric or insulation material on the substrate 408 .
- Openings 412 or vias may be formed in the dielectric layer 410 to permit access and electrical connection to the underlying transceivers 404 .
- the openings 412 may be formed by selectively removing material using standard photolithographic techniques or other known etching techniques.
- a layer 402 of conductive material or metallization may be deposited or formed on the dielectric layer 410 and in the openings 412 to contact the transceivers 404 .
- the conductive material layer 402 may couple the transceiver 404 to test output points or other contact points.
- the conductive material layer 402 may be etched to form conductive line traces to connect the individual transceivers 404 to test output points, contacts or pads, similar to pad 220 of FIG.
- test output signals or other signals from each of the transceivers 404 .
- the test output points or pads may be formed proximate to a periphery of the wafer 400 to permit coupling to external test equipment to receive the test signals.
- the conductive layer 402 and insulative layer 410 may be removed for further manufacturing or processing of the wafer 400 .
- a conductive layer, similar to layer 402 or conductive line traces may be formed, as described above, at various stages of the manufacturing process to test the integrated circuits at various stages of completion or for other purposes. Test data may be sent to the transceivers 404 wirelessly and then the test results read out via line traces of the conductive layer 402 .
- FIG. 5 is a block diagram of an example of a transceiver 500 that may be use in a system, such as the system 200 of FIG. 2 or 300 of FIG. 3 to test integrated circuits or the like in accordance with an embodiment of the present invention.
- the transceiver 500 may include a down converter 504 to convert a received radio frequency (RF) signal from an antenna 506 to an intermediate frequency (IF) signal.
- the down converter 502 may include an amplifier 508 , such as a low noise amplifier or the like, and a multiplexer 510 .
- the multiplexer 510 may mix the RF signal from the amplifier 508 with a carrier signal from a voltage controlled oscillator (VCO) 512 to provide the IF signal.
- a limiting amplifier 514 may amplify the IF signal in response to inputs from a received signal strength indicator (RSSI) 516 .
- a comparator 518 may generate a data signal in response to the amplified IF signal from the limiting amplifier 514 or RSSI 516 .
- the data signal or received signal (Rx) from the comparator 518 may be an on-off keying (OOK) data signal or the like.
- the transceiver may include a phase/frequency detector (PFD) 522 .
- the PFD 522 may receive a reference signal (Ref) or input signal and a carrier signal from the VCO 512 divided by a predetermined integer in a divide unit 524 .
- a charge pump (CP) 426 may receive an output signal from the PFD 522 .
- a filter 528 may filter selected frequency band signals from the charge pump 526 .
- the filter 528 may be a low pass filter or the like.
- the VCO 512 may receive the signal from the filter 528 .
- a power amplifier 530 may modulate a carrier signal from the VCO 512 by a data input or transmit signal (Tx) to provide an RF output signal that may be transmitted by an antenna 532 .
- the transmit modulation signal Tx may be an on-off keying (OOK) modulating signal or the like.
- FIG. 6 is a schematic diagram of an example of an antenna system 600 that may be used in a system, such as system 200 of FIG. 2 and system 300 of FIG. 3 to test integrated circuits or the like in accordance with an embodiment of the present invention.
- the antenna system 600 may be used for the antenna system 210 in FIG. 2 or the antenna system 308 in FIG. 3 .
- the antenna system 600 may include a loop antenna 602 adapted to be shared by a plurality of transceivers (not shown in FIG. 6 ), such as transceiver 500 of FIG. 5 or a similar transceiver.
- the antenna system 600 may also include a plurality of differential amplifier circuits 604 .
- the differential amplifier circuits 604 may include a pair of metal oxide semiconductor field effect transistors (MOSFETs) 606 or similar devices connected in a differential arrangement.
- MOSFETs metal oxide semiconductor field effect transistors
- the MOSFETs 606 may be either PNP or NPN transistors depending upon the polarity or whether a high or low voltage or signal is intended to be used to turn the transistors on or activate the transistors.
- Each differential amplifier circuit 604 may be associated with one of the plurality of transceivers. In operation, only one of the plurality of differential amplifier circuits is intended to be active at any given time to permit the associated transceiver to receive or transmit signals.
- the antenna system 600 may further include an inductor or a pair of inductors 608 associated with each differential amplifier 604 and that may be connected in parallel therewith.
- the inductor or pair of inductors 608 may complete the loop antenna 602 when an associated differential amplifier 604 is inactive or disabled by putting a proper voltage or signal on a gate of each MOSFET 606 to render the MOSFET inactive or non-conductive.
- Another MOSFET 610 may couple a voltage source, Vdd, to a node 612 between each pair of inductors 608 .
- the voltage source, Vdd may be coupled to the node 612 in response to an RF carrier signal or data signal from an associated one of the plurality of transceivers, such as transceiver 500 ( FIG.
- the differential amplifiers 604 associated with the active MOSFET 610 may also have an RF signal applied to their gates at the same time to cause the differential amplifier 610 to conduct and connect the antenna system 600 to ground potential. All other differential amplifiers 610 associated with non-transmitting or non-receiving transceivers will be inactive or non-conducting and the antenna loop 602 will be completed through the inductors 608 in parallel with the inactive differential amplifiers 604 .
- the antenna system 600 may be formed in the scribe lines, similar to the scribe lines 104 of FIG. 1, 208 of FIGS. 2 and 306 of FIG. 3 .
- the loop antenna 602 may extend around one or more integrated circuits defined by the scribe lines.
- the loop antenna 602 may be physically small compared to the wavelength at which the antenna 602 may operate.
- the antenna system 600 may be designed or sized to operate in the 24 Gigahertz (GHz) ISM band. At around 24 GHz, line of sight transmission may be used to establish wireless communications and thereby avoid interference among other testing units or systems in the vicinity. Additionally, because wavelength is inversely proportional to the frequency, operating at about 24 GHz will significantly reduce the size of the required antennas and thereby make them more suitable for integration on a wafer. Moreover, passive components used in a 24 GHz radio transceiver will have lower inductance and capacitance and therefore occupy less chip area and more easily fit within the scribe lines.
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Abstract
Description
- The present invention relates to integrated circuits, semiconductor chips and the like, and more particularly to a to a system and method to test an integrated circuit, semiconductor chip on a wafer.
- Testing integrated circuits, semiconductor chips and the like at various stages of the manufacturing process can be advantageous as processing adjustments may be made or other remedial operations may be performed to realize higher yields. Capturing information regarding fluctuations and failures during the manufacturing process can have a substantial impact on the overall product cost. For some emerging forms of regular logic, back-end-of-line (BEOL) processing adjustments and changes could be made to permit substantially complete utilization of what would otherwise be partially non-functioning silicon. However, testing chips during the manufacturing process and while the chips are still part of a wafer, presents many challenges.
- One means of testing chips during various stages of the manufacturing process is wafer probe testing. However, such testing is not without its limitations. Wafer probe testing is costly and limited in terms of the extent to which it may be used. During early stages of in-line manufacturing testing, the wafers must be maintained in their manufacturing environment. Additionally, wafer probe testing of all chips and collecting test data from all chips in the manufacturing environment is impractical. For end-of-line testing, the environmental issues are less of a problem, but the process is still costly. During wafer sort, probe testing is still time consuming and therefore costly and issues exist with respect to contact resistance associated with the probes which can impact overall yield.
- In accordance with an embodiment of the present invention, a system to test integrated circuits, semiconductor chips or the like formed on a wafer may include a transceiver formed on the wafer. The system may also include an antenna system that is couplable to the transceiver. The transceiver may be formed in one of a scribe line formed on the wafer, on each of the integrated circuits or dies to be tested, on another chip or die on the wafer, or in an unusable portion of the wafer. The antenna system may be formed in at least one of the same scribe line as the transceiver, in at least one other scribe line formed in the wafer, on each of the integrated circuits or dies to be tested, on another chip or die on the wafer or on an usable portion of the wafer. The antenna or antenna system may also be external to the wafer and the transceiver may be coupled to the antenna by a wafer boat, handler or similar fixture that holds the wafer during manufacturing.
- In accordance with another embodiment of the present invention, a system to test integrated circuits, semiconductor chips or the like formed on a wafer may include a plurality of transceivers. Each transceiver may be adapted to receive and transmit signals to test selected ones of a multiplicity of integrated circuits or the like formed on the wafer. Each of the transceivers may be formed at different locations on the wafer. Each transceiver may be formed in at least one of a plurality of scribe lines formed on the wafer, on each die or integrated circuit to be tested, on another die or chip on the wafer or on an unusable portion of the wafer. The system may also include a plurality of antenna systems. Each antenna system may be couplable to at least one of the plurality of transceivers. Each of the plurality of antenna systems may be formed at different locations on the wafer in at least one of the plurality of scribe lines, on a chip on the wafer or on an unusable portion of the wafer. In another embodiment of the present invention, the antenna or antenna system may be external to the wafer and the transceivers may be coupled to the antenna by a wafer boat or fixture used to hold the wafer during the manufacturing process.
- In accordance with another embodiment of the present invention, a transceiver to test integrated circuits or the like formed on a wafer may include a down converter to convert a received radio frequency (RF) signal to an intermediate frequency (IF) signal. The transceiver may also include a received signal strength indicator (RSSI) and an amplifier to amplify the IF signal in response to the RSSI. The transceiver may also include a comparator to generate a data signal in response to an amplified IF signal.
- In accordance with another embodiment of the present invention, a transceiver to test integrated circuits or the like formed on a wafer may include a phase/frequency detector to receive an input or reference signal. A charge pump may be provided to receive an output signal from the phase/frequency detector. A filter may filter signals in a selected frequency band from the charge pump. A voltage controlled oscillator may receive the filtered signal from the filter and a power amplifier may modulate a carrier frequency from the voltage controlled oscillator.
- In accordance with another embodiment of the present invention, an antenna system to test integrated circuits or the like formed on a wafer may include a loop antenna or the like adapted to be shared by a plurality of transceivers. The antenna system may also include a plurality of differential amplifier circuits. Each differential amplifier circuit may be associated with one of the plurality of transceivers, wherein only one of the plurality of differential amplifier circuits may be active at any given time to permit the associated transceiver to receive or transmit signals.
- In accordance with another embodiment of the present invention, a method of making a system to test integrated circuits or the like formed on a wafer may include forming a transceiver on the wafer. The method may also include providing an antenna system that is couplable to the transceiver. The transceiver may be formed in at least one of a scribe line formed on the wafer, on each die or integrated circuit to be tested, on another die or chip on the wafer, or on an unusable portion of the wafer. The antenna system may be formed in at least one of the same scribe line as the transceiver, in at least one other scribe line formed in the wafer, a die or chip on the wafer or an unusable portion of the wafer. In another embodiment of the present invention, the antenna or antenna system may be external to the wafer.
- In accordance with another embodiment of the present invention, a method to test integrated circuits or the like formed on a wafer may include selecting at least one integrated circuit of a plurality of integrated circuits to be tested. The method may also include performing a test or self-test on the at least one selected integrated circuit and transmitting test results via a transceiver associated with the at least one selected integrated circuit.
-
FIG. 1 is top elevation view of a wafer on which integrated circuits or the like are formed. -
FIG. 2 is a block diagram of a system to test integrated circuits or the like formed on a wafer in accordance with an embodiment of the present invention. -
FIG. 3 is a block schematic diagram of a system to test integrated circuits or the like formed on a wafer in accordance with another embodiment of the present invention. -
FIG. 4 is a partial cross-sectional view of a wafer illustrating a conductive layer to connect to transceivers formed on the wafer in accordance with an embodiment of the present invention. -
FIG. 5 is a block diagram of an example of a transceiver that may be used in a system to test integrated circuits or the like in accordance with an embodiment of the present invention. -
FIG. 6 is a schematic diagram of an example of an antenna system that may be used in a system to test integrated circuits or the like in accordance with an embodiment of the present invention. - The following detailed description of preferred embodiments refers to the accompanying drawings which illustrate specific embodiments of the invention. Other embodiments having different structures and operations do not depart from the scope of the present invention.
-
FIG. 1 is top elevation view of awafer 100 on which integratedcircuits 102, semiconductor chips or the like are formed. Each of the integratedcircuits 102 are separated by scribe lines 104 formed in a surface of thewafer 100. Afirst plurality 104 a of scribe lines may extend parallel to one another in one direction or substantially horizontally across the surface or thewafer 100. Asecond plurality 104 b of scribe lines may extend substantially parallel to one another in a different direction or substantially orthogonal to thefirst plurality 104 a of scribe lines. Thescribe lines integrated circuit 102 or semiconductor chip. Thescribe lines scribe lines system 200 to test integrated circuits illustrated inFIG. 2 or other systems, to be formed within thescribe lines circuits 102 on thewafer 100 at various stages during the manufacturing process. In at least one embodiment of the present invention, the system may be employed without the use of probes to test the integratedcircuits 102. -
FIG. 2 is a block diagram of asystem 200 to test integrated circuits (ICs) 202, semiconductor chips or the like formed on awafer 204 in accordance with an embodiment of the present invention. Only a portion of thewafer 204 andintegrated circuits 202 are shown inFIG. 2 for purposes of explanation and clarity. Theintegrated circuits 202 andwafer 204 may be similar to theintegrated circuits 102 andwafer 100 illustrated inFIG. 1 . Thesystem 200 may include atransceiver 206 formed in ascribe line 208 of thewafer 204. In other embodiments of the present invention, thetransceiver 206 may be formed at other locations on thewafer 204. For example, thetransceiver 204 may be formed on the die or as part of theintegrated circuit 202 being tested for self-testing or the like. Alternatively, thetransceiver 204 may be formed in another chip or die portion of thewafer 204 that is not used to form an integrated circuit or in an unusable portion of thewafer 204, such as thearea 106 inFIG. 1 . Thesystem 200 may also include anantenna system 210 that is couplable to thetransceiver 206 to receive and transmit signals to and from thetransceiver 206. Theantenna system 210 may also be formed in at least onescribe line 208 formed in thewafer 204 or on a surface of thewafer 204. Theantenna system 210 may be formed in thesame scribe line 208 as thetransceiver 206, or in another embodiment, theantenna system 210 may be formed in one ormore scribe lines 208 of thewafer 204. Theantenna system 210 may also be formed at other locations on thewafer 204. For example, theantenna system 210 or systems may be formed on each die orchip 202 to be tested, on another chip or die portion on thewafer 204 that is not used to form an integrated circuit or on an unusable portion of thewafer 204. Theantenna system 210 may include a loop antenna, a dipole antenna or the like, or theantenna system 210 may be an antenna array formed by loop elements, dipole elements or similar elements. - The
transceiver 206 may be coupled to a plurality ofintegrated circuits 202 by amultiplexing circuit 212 or the like to test selected ones of the plurality ofintegrated circuits 202. Thetransceiver 206 may be adapted to apply test signals to at least one selectedintegrated circuit 202 to test the selectedintegrated circuit 202 in response to theantenna system 210 receiving a testing signal or a similar signal. Theantenna system 210 may be adapted to receive testing signals and to transmit signals corresponding to results from the testing of the at least one selectedintegrated circuit 202. - In accordance with one embodiment of the present invention, an
integrated circuit 202 to be tested and an associatedtransceiver 206 may be selected by at least one of a word-line 214 or a bit-line 216. Word-lines 214 and bit-lines 216 are electrically conductive traces of metallization or other conductive material that may be formed in the scribe lines 208. The word-lines 214 may extend in one direction across thewafer 204 and the bit-lines 216 may extend substantially orthogonal to the word-lines 214 across thewafer 204. The word-lines 214 and bit-lines 216 may be accessed proximate to a periphery or edge of thewafer 204. Eachintegrated circuit 202 may be electrically connected to at least one word-line 214 and to at least one bit-line 216 so that eachintegrated circuit 202 may be addressed by at least one associated word-line 214 and bit-line 216. The word-lines 214 and bit-lines 216 may then be used to address or select a specificintegrated circuit 202 for testing or for other purposes, such as to send and receive signals from selectedintegrated circuits 202, powering selectedintegrated circuits 202 or the like. The word-lines 214 and bit-lines 216 may form a selecteddistribution scheme 218 or pattern in thescribe lines 208 to facilitate selecting an integrated circuit orcircuits 202 to be tested and an associated transceiver ortransceivers 206. The word-line/bit-line distribution scheme 218 may also be used or may be alternatively used to distribute test mode power to the selectedintegrated circuit 202 to be tested and the associatedtransceiver 206. In alternate embodiments of the present invention, thetransceiver 206 may receive power via one of a probe, a radio frequency power signal or apad 220 electrically connected to thetransceiver 206 in addition to a word-line or a bit-line. Thepad 220 may be formed proximate to a periphery of thewafer 204. Thepad 220 may be electrically connectable to apower source 222 external to thewafer 204. Only onepad 220 is shown inFIG. 2 for purposes of explanation; however, multiple pads similar to pad 220 may be formed at selected location around the periphery of thewafer 204 to distribute power to other transceivers formed on thewafer 204. - After selecting and testing a particular
integrated circuit 202 or group ofintegrated circuits 202, an associatedtransceiver 206 may be adapted to select a proper stream of test data for the particularintegrated circuit 202 under test from themultiplexing circuit 212. Thetransceiver 206 may then transmit the resulting test data to an external transceiver or test unit (not shown inFIG. 2 ) via theantenna system 210. Thetransceiver 206 may be adapted to provide one of an amplitude shift keying (ASK) modulation scheme, on-off keying (OOK) modulation or a similar modulation scheme that may permit the architecture of thetransceiver 206 to be relatively simple for formation of thetransceiver 206 in thescribe line 208. Thetransceiver 206 may receive and transmit signals to perform real-time tests periodically during fabrication of thewafer 204, such as during burn-in stress conditions or under other environmental extremes. While only onetransceiver 206 andantenna system 210 are shown inFIG. 2 for purposes of clarity and explanation, thesystem 200 may include a plurality oftransceivers 206 andantenna systems 210 similar to thesystem 300 illustrated inFIG. 3 . Thetransceivers 206 andantenna systems 210 may be located at selected locations or in a predetermined distribution to efficiently permit testing of any and allintegrated circuits 202 formed on thewafer 204. -
FIG. 3 is a block schematic diagram of asystem 300 to test integrated circuits formed on awafer 302, similar tointegrated circuits FIGS. 1 and 2 . Thesystem 300 may be similar to thesystem 200 ofFIG. 2 . Thesystem 300 may include a plurality oftransceivers 304. Each of thetransceivers 304 may be adapted to receive and transmit signals to test selected ones of a multiplicity of integrated circuits (not shown inFIG. 3 ), similar tointegrated circuits FIGS. 1 and 2 respectively. Each of thetransceivers 304 may be formed at a different location on thewafer 302 in at least one of a plurality ofscribe lines 306 formed in thewafer 302. Each of thetransceivers 304 may be coupled to one or more integrated circuits to test selected ones of the integrated circuits. A multiplexing circuit, similar to themultiplexing circuit 212 shown inFIG. 2 may be provided to couple eachtransceiver 304 to associated ones of the plurality of integrated circuits. - The
system 300 may also include a plurality ofantenna systems 308. Eachantenna system 308 may be coupled to at least one of the plurality oftransceivers 304. Eachantenna system 308 may also be formed at different locations on thewafer 302 in one or more of the scribe lines 306. Thetransceivers 304,antenna systems 308 andscribe lines 306 are not shown to scale relative to thewafer 302 and are illustrated as being much larger than actuality for purposes of explaining the present invention. As previously described, the scribe lines may be on the order of about 200 microns or more in width. Each of thetransceivers 304 andantenna systems 308 may be formed in a predetermined distribution on thewafer 302. The predetermined distribution may be adapted to effectively and efficiently test all integrated circuits at various stages of the manufacturing process and to facilitate optimum testing of a selected number of integrated circuits simultaneously. The predetermined distribution may also be adapted to minimize space utilization and to minimize electromagnetic interference with the integrated circuits during testing and betweendifferent transceivers 304 and associatedantenna systems 308. Eachtransceiver 304 or each transceiver in a subset oftransceivers 304 of the plurality of transceivers may each be adapted to receive testing signals and to transmit test result signals simultaneously on different radio frequencies or channels. As previously discussed, each of thetransceivers 304 may be adapted to provide one of an amplitude shift keying (ASK) modulation, on-off keying (OOK) modulation or a similar modulation scheme. Each of thetransceivers 304 may also be adapted to receive and transmit signals to perform real-time tests or other operations periodically during fabrication of thewafer 302. For example, thetransceiver 304 may be adapted to transmit and receive signals to perform tests under burn-in stress conditions or other environmental conditions. - The
system 300 may also include another transceiver or a system transceiver andtest unit 310 that may be located external to thewafer 302. Thesystem transceiver 310 may be adapted to transmit scan test vectors or other signals to selected ones of thetransceivers 304 on thewafer 302 and to receive test results from the selectedtransceivers 304. Each of thetransceivers 304 may communicate with thesystem transceiver 310 on different radio frequencies or channels. Thetransceivers 304 may transmit self-test data and receive and transmit scan test vectors form the external system transceiver andtest unit 310. Thesystem transceiver 310 may transmit and receive RF signals via anantenna 312. To minimize interference with other systems, the transmit power from thewafer 302 as well as theexternal transceiver 310 andantenna 312 may be kept at a low enough level so that the coverage is within a predetermined distance “D.” The predetermined distance “D” may be on the order of about one meter. - In accordance with another embodiment of the present invention, one or
more antennas 314 or an antenna system provided external to thewafer 302 may be coupleable to each of thetransceivers 304. Thetransceivers 304 may be coupled to theantenna 314 via awafer boat 316, wafer handler or other fixtures that may hold thewafer 302 during the manufacturing process. Thetransceivers 304 may transmit and receive signals via theantenna 314 to test the integrated circuits formed on thewafer 302 or for other purposes. In accordance with a further embodiment of the present invention anantenna 318 may be integrally formed or attached to thewafer boat 316 as an alternative toexternal antenna 314. Theexternal antenna 314 or thewafer boat antenna 318 may be provided in addition to theantenna systems 308 formed in thescribe lines 306 or as alternatives to theantenna systems 308. -
FIG. 4 is a partial cross-sectional view of awafer 400 illustrating aconductive layer 402 to connect totransceivers 404 formed inscribe lines 406 on thewafer 400 in accordance with an embodiment of the present invention. As previously described, thetransceivers 404, similar to thetransceivers FIGS. 2 and 3 , respectively, may be formed in thescribe lines 406 that are formed in asubstrate 408 of thewafer 400. Integrated circuits (not shown inFIG. 4 ) formed on thewafer 400 may be tested during the manufacturing process by depositing or forming alayer 410 of dielectric or insulation material on thesubstrate 408.Openings 412 or vias may be formed in thedielectric layer 410 to permit access and electrical connection to theunderlying transceivers 404. Theopenings 412 may be formed by selectively removing material using standard photolithographic techniques or other known etching techniques. Alayer 402 of conductive material or metallization may be deposited or formed on thedielectric layer 410 and in theopenings 412 to contact thetransceivers 404. Theconductive material layer 402 may couple thetransceiver 404 to test output points or other contact points. Theconductive material layer 402 may be etched to form conductive line traces to connect theindividual transceivers 404 to test output points, contacts or pads, similar to pad 220 ofFIG. 2 , to receive test output signals or other signals from each of thetransceivers 404. The test output points or pads may be formed proximate to a periphery of thewafer 400 to permit coupling to external test equipment to receive the test signals. After testing the integrated circuits, theconductive layer 402 andinsulative layer 410 may be removed for further manufacturing or processing of thewafer 400. A conductive layer, similar tolayer 402 or conductive line traces may be formed, as described above, at various stages of the manufacturing process to test the integrated circuits at various stages of completion or for other purposes. Test data may be sent to thetransceivers 404 wirelessly and then the test results read out via line traces of theconductive layer 402. -
FIG. 5 is a block diagram of an example of atransceiver 500 that may be use in a system, such as thesystem 200 ofFIG. 2 or 300 ofFIG. 3 to test integrated circuits or the like in accordance with an embodiment of the present invention. In areceiver section 502 of thetransceiver 500, thetransceiver 500 may include adown converter 504 to convert a received radio frequency (RF) signal from anantenna 506 to an intermediate frequency (IF) signal. The downconverter 502 may include anamplifier 508, such as a low noise amplifier or the like, and amultiplexer 510. Themultiplexer 510 may mix the RF signal from theamplifier 508 with a carrier signal from a voltage controlled oscillator (VCO) 512 to provide the IF signal. A limitingamplifier 514 may amplify the IF signal in response to inputs from a received signal strength indicator (RSSI) 516. Acomparator 518 may generate a data signal in response to the amplified IF signal from the limitingamplifier 514 orRSSI 516. The data signal or received signal (Rx) from thecomparator 518 may be an on-off keying (OOK) data signal or the like. - In a
transmitter section 520 of thetransceiver 500, the transceiver may include a phase/frequency detector (PFD) 522. ThePFD 522 may receive a reference signal (Ref) or input signal and a carrier signal from theVCO 512 divided by a predetermined integer in adivide unit 524. A charge pump (CP) 426 may receive an output signal from thePFD 522. Afilter 528 may filter selected frequency band signals from thecharge pump 526. Thefilter 528 may be a low pass filter or the like. TheVCO 512 may receive the signal from thefilter 528. Apower amplifier 530 may modulate a carrier signal from theVCO 512 by a data input or transmit signal (Tx) to provide an RF output signal that may be transmitted by anantenna 532. The transmit modulation signal Tx may be an on-off keying (OOK) modulating signal or the like. -
FIG. 6 is a schematic diagram of an example of anantenna system 600 that may be used in a system, such assystem 200 ofFIG. 2 andsystem 300 ofFIG. 3 to test integrated circuits or the like in accordance with an embodiment of the present invention. Theantenna system 600 may be used for theantenna system 210 inFIG. 2 or theantenna system 308 inFIG. 3 . Theantenna system 600 may include aloop antenna 602 adapted to be shared by a plurality of transceivers (not shown inFIG. 6 ), such astransceiver 500 ofFIG. 5 or a similar transceiver. Theantenna system 600 may also include a plurality ofdifferential amplifier circuits 604. Thedifferential amplifier circuits 604 may include a pair of metal oxide semiconductor field effect transistors (MOSFETs) 606 or similar devices connected in a differential arrangement. TheMOSFETs 606 may be either PNP or NPN transistors depending upon the polarity or whether a high or low voltage or signal is intended to be used to turn the transistors on or activate the transistors. Eachdifferential amplifier circuit 604 may be associated with one of the plurality of transceivers. In operation, only one of the plurality of differential amplifier circuits is intended to be active at any given time to permit the associated transceiver to receive or transmit signals. - The
antenna system 600 may further include an inductor or a pair ofinductors 608 associated with eachdifferential amplifier 604 and that may be connected in parallel therewith. The inductor or pair ofinductors 608 may complete theloop antenna 602 when an associateddifferential amplifier 604 is inactive or disabled by putting a proper voltage or signal on a gate of eachMOSFET 606 to render the MOSFET inactive or non-conductive. AnotherMOSFET 610 may couple a voltage source, Vdd, to anode 612 between each pair ofinductors 608. The voltage source, Vdd, may be coupled to thenode 612 in response to an RF carrier signal or data signal from an associated one of the plurality of transceivers, such as transceiver 500 (FIG. 5 ), being applied to a gate of theMOSFET 610 to activate theMOSFET 610. Thedifferential amplifiers 604 associated with theactive MOSFET 610 may also have an RF signal applied to their gates at the same time to cause thedifferential amplifier 610 to conduct and connect theantenna system 600 to ground potential. All otherdifferential amplifiers 610 associated with non-transmitting or non-receiving transceivers will be inactive or non-conducting and theantenna loop 602 will be completed through theinductors 608 in parallel with the inactivedifferential amplifiers 604. - The
antenna system 600 may be formed in the scribe lines, similar to the scribe lines 104 ofFIG. 1, 208 ofFIGS. 2 and 306 ofFIG. 3 . Theloop antenna 602 may extend around one or more integrated circuits defined by the scribe lines. Theloop antenna 602 may be physically small compared to the wavelength at which theantenna 602 may operate. Theantenna system 600 may be designed or sized to operate in the 24 Gigahertz (GHz) ISM band. At around 24 GHz, line of sight transmission may be used to establish wireless communications and thereby avoid interference among other testing units or systems in the vicinity. Additionally, because wavelength is inversely proportional to the frequency, operating at about 24 GHz will significantly reduce the size of the required antennas and thereby make them more suitable for integration on a wafer. Moreover, passive components used in a 24 GHz radio transceiver will have lower inductance and capacitance and therefore occupy less chip area and more easily fit within the scribe lines. - Although specific embodiments have been illustrated and described herein, those of ordinary skill in the art appreciate that any arrangement which is calculated to achieve the same purpose may be substituted for the specific embodiments shown and that the invention has other applications in other environments. This application is intended to cover any adaptations or variations of the present invention. The following claims are in no way intended to limit the scope of the invention to the specific embodiments described herein.
Claims (70)
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